Metal-carbon particle composite material and method for manufacturing same

Abstract

A metal-carbon particle composite material (30) is provided with one or more flake-like graphite particle dispersion layers (1) in which flake-like graphite particles (1a) as carbon particles are dispersed in a metal matrix (9), one or more carbon fiber dispersion layers (2) in which carbon fibers (2a) as carbon particles are dispersed in a metal matrix (9), and one or more metal layers (3) formed by the metal matrix (9) in a laminated manner. One or more flake-like graphite particle dispersion layers (1), one or more carbon fiber dispersion layers (2), and one or more metal layers (3) are integrally bonded. One of the flake-like graphite particle dispersion layer (1) and the carbon fiber dispersion layer (2) and the metal layer (3) are alternately laminated substantially entirely in the thickness direction of the composite material (30).

1 - 5 . (canceled) 
     
     
         6 . A metal-carbon particle composite material in which one or more flake-like graphite particle dispersion layers in which flake-like graphite particles as carbon particles are dispersed in a metal matrix, one or more carbon fiber dispersion layers in which carbon fibers as carbon particles are dispersed in the metal matrix, and one or more metal layers formed of the metal matrix are integrally bonded in a laminated manner. 
     
     
         7 . The metal-carbon particle composite material as recited in  claim 6 ,
 wherein the flake-like graphite particle dispersion layer, the carbon fiber dispersion layer, and the metal layer are arranged in a state of being laminated in a regular lamination order substantially entirely in a thickness direction of the composite material.   
     
     
         8 . A cooling device for a power module, comprising:
 a plurality of cooling device constituent layers integrally bonded in a laminated manner,   wherein at least one of the plurality of cooling device constituent layers is made of the metal-carbon particle composite material as recited in  claim 6 .   
     
     
         9 . A method of producing a metal-carbon particle composite material, comprising:
 a step of obtaining a flake-like graphite particle coated foil in which a flake-like graphite particle layer is formed on a first metal foil by coating a first coating liquid containing flake-like graphite particles as carbon particles and a first binder on the first metal foil and drying it;   a step of obtaining a carbon fiber coated foil in which a carbon fiber layer is formed on a second metal foil by coating a second coating liquid containing carbon fibers as carbon particles and a second binder on the second metal foil and drying it;   a step of forming a laminate in a state in which one or more flake-like graphite particle coated foils and one or more carbon fiber coated foils are laminated; and   a step of integrally bonding the one or more flake-like graphite particle coated foils and the one or more carbon fiber coated foils collectively by heating the laminate.   
     
     
         10 . The method of producing a metal-carbon particle composite material as recited in  claim 9 ,
 wherein in the step of forming the laminate, the laminate is formed such that the flake-like graphite particle coated foil and the carbon fiber coated foil are laminated in a regular lamination order substantially entirely in a thickness direction of the laminate.